PARTICULATE, HC1, HF and VISUAL

EMISSIONS

TESTING ON THE DRY INJECTION

FABRIC

FILTER

BAGHOUSE

(DIFF) :'BORAL BRICKS 700 South Long Street EAST SPENCER

(ROWAN

COUNTY),

NC 28039 (704) 636-1031

Plant Contact

Telephone

Number (704) 636-7865

Plant Facsimile

Number Source Testing Conducted: July 20, 2007 ATC Project Number P-07099

Provic•ng Qua,#ty Air Tes•ng and Consu•'n.g Ser•ces Since 1981. ANALYTICAL TESTING

CONSULTANTS,

INC. 301 Brookdale

Street Kannapolis, N. C. 28083 (704) 932-3193

telephone (800) 733-3193

toll-free (704) 932-0570

facsimile corp@atc-net.net e-mail www.atc-net.net Web site Distribution: Mr. Frank Porter (Four copies) Mr. Barry Schenk (One copy) Issue Date: August 8, 2007TABLE OF CONTENTS Page No, Introduction 3 Certification of Results 3 Source Description 4 Results Summary 5 Results, Conclusions

and Comments 7 Sampling and Analytical

Procedures 8 References 10 Emission Calculations 11 HC1/HF Mass Loading

Calculation 12 HC1/HF Outlet Emission

Rate Calculation 13 Particulate Emission

Rate Calculation 14 Isokinetic Data and Calculations

(Inlet and Outlet) 15 Moisture Data/Isokinetic

Sampling

Rate Equation

(Inlet and Outlet) 21 Sample Calculations 23 Nomenclature 25 Calculation Formulae 27 Appendix 30 Approved Test Plan A1 NCDAQ Plan Approval

Letter A25 Isokinetic Sampling

Data Sheets A27 Impinger Data Records A36 Portable Oxygen/Carbon

Dioxide

Measurements A37 Source Surveys/Equal

Areas A43 Gravimetric Lab Report A51 LELAP Certification A67 I-IF/HC1 Laboratory

Report A72 Visible Emissions

Observations A79 VE Observers

Certification A82 Process Data A84 Calibration Data A85

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 2 of 30INTRODUCTION
This

report presents

the results of particulate,

hydrogen

chloride,

hydrogen

fluoride

and visible emissions testing performed

on the inlet/outlet

of the new dry injection

fabric filter baghouse recently installed

on Brick Kiln #6 at Boral Bricks, Inc in East Spencer,

North Carolina. Emissions testing were conducted

while the kiln was fired at a rate of 25.2 tons fired product per hour.The following

table outlines

the methodology

utilized. US EPA Methodology 2Inlet/Outlet 3a Inlet/Outlet4Inlet/Outlet Description Determination of Volumetric

Flow rates Oxygen/Carbon dioxide concentration determinations Determination of Stack Moisture Content

Isokinetic Sampling? NoNo Notes S-type pitottube

Yes Determination of TSP particulate

Yes

3 1-hr runs Outlet Only9

Determination

of Opacity No 26a Determination

of Hydrogen

Halide and Combined

with M5 on Inlet/Outlet Halogen

Emissions

from Stationary

Yes Sources

Outlet/M4

on Inlet Semi-continuous analyzers Combined with USEPA M5 outlet/26A

inlet

Testing was conducted

by ANALYTICAL

TESTING

CONSULTANTS,

INC., Kannapolis, North Carolina.

Members

of the test team were Jason Treutel,

Stewart Meadows,

Brian Jones and Kent Childers.

Mr. Frank Porter and Mr. Barry Schenk of Boral Bricks performed

the visual emissions observations.CERTIFICATION OF RESULTS

BY TEST FIRM "I certify under penalty of law that I believe the information

provided

in this document

is true, accurate and complete.

I am aware that there are significant

civil and criminal penalties,

including

the possibility of fine or imprisonment

or both, for submitting

false, inaccurate

or incomplete

information." •. _____C'••

•

•///,•/•,7 •//••Signature/Date Sign•tur•e/Date Y • Report Author Report Review W. Keith Poole• Technical

Director Printed Name/Title Bill Kissel• President Printed Name/Title Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) Po7099 Page 3 of 30SOURCE DESCRIPTION Testing was conducted

on the inlet/outlet

of the new dry injection

fabric filter (DIFF) baghouse that controls

acid gas (HC1 and HF) and particulate

emissions

released

from the wood-waste fired Brick Kiln #6 at Boral Bricks, located in East Spencer,

North Carolina.

The DIFF system injects hydrated

lime into the brick kiln exhaust stream which reacts with HF and HC1 to form calcium fluoride

and calcium

chloride.

The spent lime (CaF and CaC1) is removed

from the exhaust air stream by bagfilters

and is transported

off site for disposal.

The baghouse

exhaust gas contains

un-reacted

pollutants

and particulate

matter. "Green" brick are stacked on drying racks and placed in a warming

room, where initial drying
occurs. The warming

room is supplied

with waste heat from the cooling section of the kiln. From the warming

room, bricks enter the dryer where the temperature

is raised and most of the process water is removed

before entering

the kiln. In the kiln, final evaporation

of the process water takes place as well as oxidation,

vitrification,

and the cooling process.

All heat used in this. process is formed in the kiln and waste heat is used for the dryer and warming

room with no other supplementary

heat. After exiting the kiln, bricks are packaged

and stored on site for sale. The brick production

rate during testing was 25.2 tons per hour.

Boral'Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 4 of 30S YS TEM RESULTS

SUMMARY Boral Bricks DIFF •aghouse

TEST DATE

07/20/07 PARAMETER Run #1 Run #2 Run #3 GENERAL QS, FLOW, ACFM

100,309

106,524

113,368 Q STD DRY, FLOWSCFM 52,519

54,325

57,437 Vm S TD (ft3)

42.77

45.31

48.43 %1 98.44

100.82

101.93 Production Rate (tons per hour fired brick) HCI/HF MASS LOADING

RATE PMRc (Ibs/hr)-HCI

2.226

2.189

2.118 Cs (GR/SCFD)-HCI 0.0049

0.0047

0.0043 PMRc (Ibs/hr)-HF

19.17

20.46

22.12 Cs (GR/SCFD)-HF 0.0426

0.0439

0.0449
HCI/HF EMISSION

RA TE PMRc (Ibs/hr)-HCI

< Cs (GR/SCFD)-HCI

< HCI Emissions (/b/ton fired brick) PMRc (Ibs/hr)-HF

< Cs (GR/SCFD)-HF

< HF Emissions (/b/ton fired brick)

0.153

0.133

0.130 3.07E-04 2.58E-04

2.58E-04

0.153 0.133

0.130 3.07E-04 2.58E-04

2.58E-04 A VERA GE
t06,73354,760

25.2

2.1780.004620.5850.0438

0.138 2.74E-04
5.49E-030.138 2.74E-04
5.49E-03
Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 5 of 30S YS TEM RESULTS

SUMMARY Boral Bricks DIFF Baghouse

Exhaust
TEST DATE

07/20/07 PARAMETER Run #1 Run #2 Run #3 GENERAL QS, FLOW, ACFM

108943

112626

113798 Q STD DRY, FLOW SCFM

58285

59895

58595 Vm STD (ft3)

40.27

41.85

41.90 %1 98.12

99.24

101.56 Production Rate (tons per hour fired brick) PARTICULA TE EMISSIONS PMRc (Ibs/hr)

3.964

2.707

0.481 Cs (GR/SCFD)

0.0079

0.0053

0.0010 PM Emissions

(/b/ton) A VERA GE

11178958925

25.2

2.3840.00470,095

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 6 of 30RESULTS, CONCLUSIONS AND COMMENTS Results are presented

in the preceding

Summary.

Additional

information

may be reviewed

in the Calculations and Appendices

sections

of this report. Emissions Results-Inlet Mean measured

stack velocities

on the seventy inch (70") horizontal

inlet duct were 66.56 feet per second yielding

an actual volumetric

flow rate of 106,733

cubic feet per minute.

The volumetric air flow rate was standardized

to a mean 54,760 cubic feet per minute based upon stack conditions

(moisture,

temperature,

static pressure

and station pressure). Inlet loading mass rates of hydrogen

fluoride

were a mean 20.59 pounds per hour; HC1 averaged 2.18 lbs/hr. Results were compared

to the calculated

emission

levels of these constituents

to determine removal

efficiency. .OutletThe mean measured

stack velocity

of the seventy-five

inch (75") outlet duct was 60.73 feet per second yielding

an actual volumetric

flow rate of 111,789

cubic feet per minute.

Standardized flow rates (mean=58,925)

were utilized

in calculations

of mass emissions

of PM, HC1 and HF. Particulate emissions

from the exhaust of the dry injection

fabric filter baghouse

(DIFF) averaged 2.38 lbs/hr and 0.095 lbs PM per ton of fired product,

well in compliance

with 40 CFR 63 Subpart JJJJJ, table 1 emission

limitations

of 0.42 lbs/ton. Hydrogen fluoride

was not detected

in any of the outlet samples;

emissions

averaged

<0.138 lbs/hr and <5.49e -°3 lbs/ton fired product

yielding

a removal

efficiency

of >99.3%

(calculated

at the detection

limit). The DIFF Baghouse

was shown to be in compliance

with the emission limitation of 0.057 lbs/ton. Hydrogen chloride

was also not detected.

Estimated

emissions,

based on the in-stack

detection limit, are < 0.138 lbs per hour yielding

a process-related

emission

rate of <5.49e "°3 lbs/ton of fired product,

well in compliance

with the Subpart JJJJJ standard

of 0.26 lbs/ton.

Removal efficiency of hydrogen

chloride

was calculated

at >93.6%. No visible emissions

were observed. Sampling and Analysis

Notes Sampling and analyses

were accomplished

according

to the site-specific

test plan submitted

to NCDENR on December

21, 2006. An approval

letter was received

on February

6, 2007. Approval for the re-test was included

in a letter from Mr. David Hughes of NCDENR

dated 7/13/2007. A copy of this letter and the test plan are included

in the appendix

to this report.
Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 7 of 30SAMPLING AND ANALYTICAL

PROCEDURES TSP particulate

emission

testing and analysis

were performed

according

to procedures

developed by the U. S. Environmental

Protection

Agency

(USEPA)

and referred

to as Method

5. Sampling port locations

and number

of test points to be used were determined

according

to Method

1. The above federal test methods

appear in the Code of Federal Regulations

(Reference

1). TSP measurements

were combined

with US EPA method 26a for determinations

of hydrogen halides and halogens;

only the halide and PM portion of the sampling

train was of concern.

A standard US EPA method

5/26a all-glass

sampling

train was utilized that employed

pyrex or quartz glass nozzles and probe liners, pre-tared

3" round Pallflex

quartz filters (lot #55356),

and Teflon filter supports.

The condenser

train consisted

of five glass impingers

connected sequentially. The first two impingers

were each charged with 100 ml of 0.1 N H2SO4; the third and fourth were filled with 100 ml of 0.1 N NaOH.

The final impinger

was initially

charged with 300 grams of silica gel. All sample recovery

was conducted

in the on-site field trailer. Condenser train acid collections

were measured

and transferred

to 500 ml Nalgene

samples bottles. The sodium hydroxide

fractions

were measured

and discarded

since no further analysis
was required.

The front half of the sampling

train (nozzle, probe and front half of the filter bell)
was rinsed with reagent grade acetone

and stored in 500 ml Nalgene®

bottles until analysis. Liquid levels were marked on the sampling

bottles with a grease pencil. Test point locations

and sampling

port placement

for velocity

traverses

are shown in the data sheets. Test point locations

were calculated

based upon an outlet stack diameter

of 75" and inlet stack diameter

of 70". Upstreams/downstreams on the exhaust dictated

maximum

sampling points (24) while twelve total test points were measured

on the inlet. Laboratory equipment

that was utilized for the gravimetric

sample analysis

included

the following:1) Precisa 303A Analytical

Lab Balance-certification and annual maintenance

by Applied Weight Technologies,

Inc. (completed

3/2/2006). 2) Prior to each use, the balance

is calibrated

with NIST Traceable

weights-0.5000,

5.0000, 50.0000, and 100.0000

grams, and 3) a Nalgene®

5317-0180

Desiccator

cabinet with indicating

desiccant. Prior to the field test, filter media were prepared

by sequentially

numbering

Pallflex

quartz filters with a non-bleeding

marker and oven drying.

Duplicate

weights

were then performed

on the filters to reach a constant

weight.

Additionally,

sufficient

quantities

of numbered

150ml Griffin beakers were thoroughly

washed with warm, soapy water and oven-dried.

Once cooled, the beakers were also weighed

to a constant

weight and stored in the dessicator

cabinet until needed.

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 8 of 30SAMPLING AND ANALYTICAL

PROCEDURES (continued) After recovery,

each filter was stored individually

in petri dishes until transferred

to the desiccator for a period of no less than twenty-four

hours at room temperature

and constant relative humidity;

filters were then weighed

to a constant

weight (to the nearest 0.1mgweighings over minimum

of six hour period). A blank of the acetone reagent was collected

in the field, along with the samples

and analyzed side by side. An appropriate

portion of acetone

(density

0.788 mg/1) was evaporated.

The maximum allowable

residue according

to US EPA QA/QC

documentation

is 0.0001%

grams. The net gain of the acetone blank was applied based upon this and a ratio of the volume of the sample to the volume of the blank according

to the following

example.
0.0005 x VsampleWBlank
A filter blank was processed

in conjunction

with the samples

and is recorded

in the gravimetric lab report. This was for QA/QC purposes

only.

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 9 of 30REFERENCES CODE OF FEDERAL

REGULATIONS,

Title 40, Part 60, Appendix

A, July 1, 2006.

B0ral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 10 of 30CALCULATIONS
HF/HC1 Inlet Loading

Calculations HF/HCI Emissions

Calculations Particulate Emissions

Calculations Isokinetic Run Data InletOutlet Moisture Data/Isokinetic

Sampling

Rate Equation Sample Calculations Nomenclature Calculation Formulae

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 11 of 30HCI/HF Inlet Loading

Rate Calculation
LOCATION: Boral Bricks SOURCE: DIFF Baghouse

Inlet
DATA Run #1 Run #2 Run #3 DATE 07/20/07

07/20/07

07/20/07 RUN TIME (min)

60.00

60.00

60.00 Dn (in)

0.260

0,260

0.260 An (ft2)

3,69E-04

3.69E-04

3.69E-04 AVG DH (in H20)

1.68

1.87

2.09 P ATM (in Hg)

29,25

29.25

29.25 Pm (in Hg)

29.37

29.39

29.40 Ps (GAUGE)

-1.30

-1.30

-1.30 Ps (INHG)

29.15

29.15

29.15 Tm (F)

82.58

87.67

88.92 Tm (R)

542.27

547.36

548.61 Vm (ft3)

45.47

48.60

52.04 Vm STD (ft3)

42.77

45.31

48.43 VLQ (ml)

64.90

88.20

98.90 VV STD (ft3)

3.06

4.16

4,66 VSTD (ft3)

45.83

49.47

53.10 %M 6,68

8.41

8.78 % SVP

100.00

100,00

100.00 MD 0,933

0.916

0,912 MWD 29.17

29.20

29.26 M 28.43

28.25

28.27 Ts (F)

457.33

464.33

466.58 Ts (R)

917.02

924.02

926.27 SUM SQRT DP

9.94

10.48

11.15 N DP

12.00

12.00

12.00 AVG SQRT DP

0.83

0.87

0.93 CP 0.84

0.84

0.84 Vs (ft/s)

62.56

66.43

70.70 Ds (in)

70.00

70.00

70.00 As (ft2)

26.73

26.73

26.73 QS, FLOW, ACFM

"100,309

"106,524

'113,368 Q STD (ft3/min)

56.277

59,312

62,969 Q STD DRY, FLOWSCFM

'52,519

54,325

57,437 WT (gm)-HCI

0.0137

0.0138

0.0135 WT (gm)-HF

0.1180

0.1290

0.1410 %1 98.44

100.82

101.93 %C02 3,17

3.33

3.75 %02 ,16.66

16.56

16.60 %C0 0.00

0.00

0.00 %N2 80.17

80.11

79.65 AVERAGE

7.96

462.75922.44

66.56 106,73359,51954,760

3.4216.61 PMRc(Ibs/hr)-HCl "2.226

2.189

2,118

2.178 Cs (GR/SCFD)-HCI

0.0049

0.0047

0.0043

0.0046 PMRc (Ibs/hr),HF

,19,170

"20.463

22.123

20.585 Cs (GR/SCFD)-HF

0.0426

0.0439

0.0449

0.0438 Theoretical amount of moisture that Ts can hold, If %M>%SVP,

%SVP will be utilized in calculations.
Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 12 of 30HCI/HF Emission

Rate Calculation
LOCATION: Boral Bricks SOURCE: DIFF Baghouse

Outlet (Kiln #6) DATA Run #1 Run #2 Run #3 DATE 07/20/07

07/20/07

07/20/07 RUN TIME (min)

60.00

60.00

60.00 Dn (in)

0.257

0.257

0.257 An (ft2)

3.60E-04

3.60E-04

3.60E-04 AVG DH (in H20)

1.71

1.82

1.82 P ATM (in Hg)

29.25

29.25

29.25 Pm (in Hg)

29.38

29.38

29.38 Ps (GAUGE)

-0.42

-0.42

-0.42 Ps (IN HG)

29.22

29.22

29.22 Tm (F)

84.33

87.00

87.38 Tm (R)

544.02

546.69

547.07 Vm (ft3)

42.30

44.17

44.25 Vm STD (ft3)

40.27

41.85

41.90 VLQ (ml)

55.00

52.60

81.50 VVSTD (ft3)

2.59

2.48

3.84 VSTD (ft3)

42.86

44.33

45.74 %M 6.05

5.59

8.40 % SVP

100.00

100.00

100.00 MD 0.939

0.944

0.916 MWD 29.13

29.14

29.15 M 28.46

28.51

28.21 Ts (F)

445.79

455.67

457.58 Ts (R)

905.48

915.36

917.27 SUM SQRT DP

18.96

19.51

19.59 N DP

24.00

24.00

24.00 AVG SQRTDP

0.79

0.81

0.82 CP 0.84

0.84

0.84 Vs (ft/s)

59.18

61.18

61.82 Ds (in)

75,00

75.00

75.00 As (ft2)

30.68

30.68

30.68 QS, FLOW, ACFM

108,943

-112,626

"113,798 Q STD (ft3/min)

62,038

63,443

63,970 Q STD DRY, FLOWSCFM

58,285

59,895

58,595 WT(gm).HCI < 0.0008

0.0007

0.0007 WT (gm)-HF < 0.0008

0.0007

0.0007 %1 98.12

99.24

101.56 %C02 3.00

3.00

3.00 %02 ,16.37

16.45

16.80 %C0 0.00

0.00

0.00 %N2 80.63

80.55

80.20 PMRc (Ibs/hr),HCI

< 0.153

0.133

0.130 PMRc (Ibs/hr)-HF

< 0.153

0.133

0.130 Cs (GR/SCFD),HCI

< 0.0003

0.0003

0.0003 Cs (GR/SCFD)-HF

< 0,0003

0.0003

0.0003 Theoretical amount of moisture that Ts can hold. If %M>%SVP,

%SVP will be utilized in calculations,

AVERAGE

6.68

453.01912.70

60.73 11t,78963,15058,925

3.0016.54

0.1380.1380.00030.00031

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 13 of 30DATE SOURCE Run #1 POINT #

ISOKINETIC

DATA AND CALCULATIONS 07/20/07 DIFF Baghouse

Inlet K=

2,4327 Tm Ts

dp

dH SQRT DP

% 02 % C02 Fuel Factor Fo A1 75

451

0.70

1.70

0.837

17.0 A2 77

458

0.80

1.95

0.894

16.4 A3 78

460

0.88

2.14

0.938

16.5

3.5

1.26 A4 79

461

0.75

1.82

0.866

16.5 A5 81

462

0.60

1.46

0.775

16.6

3.5

1.23 A6 82

450

0.43

1.05

0.656

16.5 B1 84

458

0.65

1.58

0.806

16.5 B2 85

459

0,75

1.82

0.866

16.5 B3 86

463

0.80

1.95

0.894

16.5 B4 87

461

0.79

1,92

0.889

16.4 B5 88

450

0.59

1.44

0,768

18.2

2.5

1.08 B6 89

455

0.56

1.36

0.748 457.33 Initial 583.24 Final 628.71 Total 45.47

1.68

9.937

16.69 corrected per 6C.1

16.66 % N2 (BY DIFFERENCE) %Excess Air

Calibration Actual Gas Zero 0,0 • 10.53 • 19.01

Calibration

Data Instrument Reading Pre- -Post

Pre0.0 0,0 0.00 10.5 10.6 0.14 19.0 n/a 0.05 Based upon 2% of span value (21%) % Error* 82.58 Vm(ft3) 3.17

1.19 80.17 369.66

-Post0.000.33n/a

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 15 of 30DATE SOURCE Run #2 POINT #

ISOKINETIC

DATA AND CALCULATIONS 07/20/07 DIFF Baghouse

Inlet

Tm

K 2.4317dH SQRT DP

%02 A1 85

464

0.68

1.65

0.825

17.0 A2 85

462

0.65

1.58

0.806

16.4 A3 86

470

0.75

1.82

0.866

16.5 A4 87

460

0.92

2.24

0.959

17.0 A5 88

462

0.75

1.82

0.866

16.5 A6 89

447

0.63

1.53

0.794 B1 88

467

0.85

2.07

0.922

16.4 B2 88

471

0.92

2.24

0.959

16.5 B3 89

467

0.95

2.31

0.975

16.5 B4 89

469

0.84

2.04

0.917

16.6 B5 89

468

0.67

1.63

0.819

16.5 B6 89

465

0.60

1.46

0.775 87.67 Vm(ft3) 484.33 Initial

629.08 Final 677.68 Total 48.598

1.87

10.481

16.59 corrected per 8C-1

16.56 % N2 (BY DIFFERENCE) %Excess Air

Calibration Actual Gas Zero 0.0 • 10.53 Hi-Ran_qg. 19.01

Calibration

Data Instrument Reading Pre- -Post

Pre0.0 0.0 0,00 10.6 10,5 0.33 n/a n/a n/a Based upon 2% of span value (21%) % Error* % C02 Fuel FactorFo 3.0 1.30 3.5 1.29

3.5 1.26
3.33 1.28 80.11360.75

.Post0.000.14n/a

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 16 of 30DATE SOURCE Run #3 POINT #A1A2A3A4A5A6B1B2B3B4B5B6

ISOKINETIC

DATA AND CALCULATIONS 07/20/07 DIFF Baghouse

Inlet K=

2.4174 Tm Ts

dp

dH SQRT DP

% 02 % C02 Fuel Factor Fo 82 467

0.80

1.93

0.894

16.4

3.5

1.29 83 473

0.87

2.10

0.933

16.5 85 469

0.95

2.30

0.975

16.5

4.0

1.10 87 471

0.94

2.27

0.970

16.3 87 467

0.90

2.18

0.949

16.4 89 467

0.80

1.93

0.894

16.4 89 470

0.87

2.10

0.933

16.5 91 458

1.03

2.49

1.015

16.3 92 465

0.94

2.27

0.970

16.4 93 468

0.84

2.03

0.917

16.3

4.0

1.15 94 461

0.74

1.79

0.860

16.7

3.5

1.20 95 463

0.70

1.69

0.837 88.92 Vm(ft3) 466.58 Initial

678.12 Final 730.15 Total 52.038

2.09

11.145

16.43 corrected per 6C-1

16. 60 % N2 (BY DIFFERENCE) %Excess Air

Calibration Actual Gas Zero 0.0 • 10.53 Hi-Ran¢j• 19.01

Calibration

Data 3.75

1.18 79.65 375.36

Instrument Reading

% Error* Pre- -Post

Pre-

-Post 0.0 -0.1 0.00

0.48 10.5 10.3 0.14

1.10 n/a n/a n/a

n/a Based upon 2% of span value (21%)

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 17 of 30DATE SOURCE ISOKINETIC

DATA AND CALCULATIONS 07/20/07 DIFF Baghouse

Outlet (Kiln #6) Run #1 K=

2.7168 POINT #

Tm

Ts

dp

dH SQRT DP

% 02 % C02 Fuel FactorFo A1 77

441

0.80

2.17

0.894

16.6

3.0

1.43 A2 78

442

0.72

1.96

0.849 A3 79

443

0.70

1.90

0.837

16.4

3.0

1.50 A4 79

443

0.71

1.93

0.843 A5 80

444

0.67

1.82

0.819

16.4

3.0

1.50 A6 81

444

0.65

1.77

0.806 A7 81

445

0.53

1.44

0.728 A8 82

446

0.56

1.52

0.748 A9 82

447

0.56

1,52

0.748 AIO 83

446

0.55

1.49

0.742 All 83

446

0.54

1.47

0.735 A12 83

436

0.52

1.41

0.721 B1 84

438

0.48

1,30

0.693 B2 85

448

0.51

1.39

0.714 B3 86

449

0.51

1.39

0.714

16.5

3.0

1.47 B4 87

448

0.51

1.39

0.714 B5 88

448

0.53

1.44

0.728

16.6

3.0

1.43 B6 88

449

0.54

1.47

0.735 B7 88

450

0.76

2.06

0.872 B8 89

450

0.67

1.82

0.819

16.4

3.0

1.50 B9 89

450

0.75

2.04

0.866 BIO 90

451

0.73

1.98

0.854 Bll 91

448

0.77

2.09

0.877 B12 91

447

0.81

2.20

0.900 84.33 Vm(ft3) InitialFinalTotal 1.71

18.956

16.48 corrected per 6C-1

16.37 245.43 % N2 (BY DIFFERENCE) 287.7342.30 %Excess Air

Calibration Gas Zero Calibration

Data Actual Instrument Reading Pre- -Post

Pre0.0 0.0

0.0 0.00 10.53 10.6

10.6 0.33 19.01 19.2

n/a 0.90 Based upon 2% of span value (21%) Error* 3.00

1.47 80.63333.45

-Post0.000.33n/a

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 18 of 30DATE SOURCE ISOKINETIC

DATA AND CALCULATIONS 07/20/07 DIFF Baghouse

Outlet (Kiln #6) Run #2 K= POINT #

Tm

Ts

dp 2.7351dH SQRT DP

%02 A1 84

440

0.65

.78 0.806

16.6 A2 84

455

0.75

2.05

0.866 A3 84

455

0.67

1.83

0.819 A4 84

455

0.71

1.94

0.843 A5 85

456

0.68

1.86

0.825 A6 85

457

0.75

2.05

0.866

16.6 A7 86

457

0.71

1.94

0.843 A8 86

457

0.70

1.91

0.837

16.5 A9 87

457

0.60

1.64

0.775 AIO 87

457

0.63

1.72

0.794 All 87

456

0.57

1.56

0.755 A12 88

452

0.59

1.61

0.768 B1 87

452

0.53

1.45

0.728 B2 88

457

0.53

1.45

0.728

16.8 B3 88

457

0.55

1.50

0.742 B4 88

458

0.54

1.48

0.735 B5 88

458

0.55

1.50

0.742

16.6 B6 88

457

0.82

2.24

0.906 B7 89

458

0.71

1.94

0.843 B8 89

458

0.52

1.42

0.721

16.7 B9 89

459

0.78

2.13

0.883 BIO 89

459

0.83

2.27

0.911 Bll 89

457

0.85

2.32

0.922 B12 89

452

0.73

2.00

0.854 87.00 Vm(ft3) 455.67 Initial

287.93 Final 332.10 Total 44.17

1.82

19.509

16.63 corrected per 6C-1

16.45 % N2 (BY DIFFERENCE) %Excess Air

Calibration Actual Gas Zero 0.0 Mid-Ranoe 10.53 Hi-Rancle 19.01

Calibration

Data Instrument Reading Pre- -Post

Pre0.0 0.0 0.00 10,6 10.7 0.33 n/a n/a n/a Based upon 2% of span value (21%) % Error* % C02 Fuel FactorFo 3.0 1.43

3.0 1.43 3.0 1.47

3.0 1.37
3.0 1.43

3.0 1.40

3.00 1.42 80.55341.18

-Post0.000.8'1n/a

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 19 of 30DATE SOURCE ISOKINETIC

DATA AND CALCULATIONS 07/20/07 DIFF Baghouse

Outlet (Kiln #6) Run #3 K=

2.7195 POINT #

Tm

Ts

dp

dH SQRT DP

% 02 % C02 Fuel Factor Fo A1 83

457

0.68

1.85

0,825

16.8

3.0

1.37 A2 84

457

0.64

1.74

0.800 A3 84

457

0.75

2.04

0.866 A4 84

458

0.73

1.99

0.854

16.9

3.0

1.33 A5 84

457

0.70

1.90

0.837 A6 85

458

0.78

2.12

0.883 A7 85

458

0.63

1.71

0.794 A8 86

459

0.63

1.71

0.794

16.7

3.0

1.40 A9 87

459

0,67

1.82

0.819 AIO 87

459

0.66

1.79

0.812 All 88

456

0.60

1.63

0.775 A12 88

452

0.60

1,63

0.775 B1 88

451

0.53

1.44

0.728 B2 88

459

0.56

1.52

0.748

16.6

3.0

1.43 B3 88

460

0.60

1.63

0.775 B4 89

459

0.55

1.50

0,742 B5 89

459

0,52

1.41

0.721 B6 89

458

0.61

1.66

0.781

16.7

3.0

1.40 B7 89

458

0.71

1.93

0.843 B8 90

459

0.70

1.90

0.837 B9 90

459

0.80

2.18

0.894

16.8

3.0

1.37 BIO 90

460

0.87

2.37

0.933 Bll 91

460

0.83

2.26

0.911 B12 91

453

0.71

1.93

0.843 87.38 Vm(ft3) 457.58 InitialFinalTotal 1.82

19.587

16.75 corrected per 6C.1

16.80 332.32 % N2 (BY DIFFERENCE) 376.5744.25 %Excess Air

Calibration Gas Zero Calibration

Data Actual Instrument Reading Pre- -Post

Pre0.0 0.0

0.0 0.00 10.53 10.7

10.3 0.81 19.01 n/a

n/a n/a Based upon 2% of span value (21%) % Error* 3.00

1.38 80.20383.91

-Post0.001.10n/a

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 20 of 30Run #1 BEGINNING ENDINGNET MOISTURE

DATA DIFF Baghouse

Inlet 7/20/2007 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 0.1N H SO 0.1N H SO 0.1N NaOH 300 g SiO 100 100

200

300.0 136 120

200

308.9 36 20

0

8.9 TOTALS
64,9

Run #2 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 0.1NH2S04 O.1NH2SO

0.1NNaOH

300 g SiO2 TOTALS BEGINNING 100

100

200

300.0 ENDING 150

118

204

316.2 NET 50

18

4 16.2

88.2

Run #3 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. O.1N H SO 0.1N H SO O.1N NaOH 300 g SiO2 BEGINNING 100

100

200

300.0 ENDING 162

120

207

309.9 NET 62

20

7

9.9 ISOKINETIC SAMPLING

RATE CALCULATION dH KdP K (846.72*Dn^4*dH@*Cp^2*(1-Bw)^2*Md*Tm*Ps)/(Ms*Ts*Pm)
Run #1 Run #2 Run #3 Module ID Apex #1 Apex #1 Apex #1 Dn 0.260

0.260

0.260 dH@ 1.638

1.638

1.638 Y, gamma factor

0.984

0.984

0.984 Cp 0.84

0.84

0.84 Bw(FRACTION, NOT%)

0.05

0.05

0.05 Md 29.00

29.00

29.00 Pbar 29.25

29.25

29.25 PS (GAUGE)

-1.30

-1.30

-1.30 Ps 29.15

29.15

29.15 Tm, F

85

88

88 Tm, R 544.69

547.69

547.69 Ms 28.45

28.45

28.45 Ts, F

455

460

465 Ts, R '914.69

919.69

924.69 Pm 29.36

29.37

29.39 K 2.4327

2.4317

2.4174 Terminology Ms=APPARENT STACK GAS MOLECULAR

WEIGHT =Md(1-Bw)+18Bw Md=DRY GAS MOLECULAR

WEIGHT (29) OR =(0.44*%CO2)+(0.32*%O2)+(0.28*(%N2+%CO)) Ps GAUGE=STACK

STATIC PRESSURE

(IN. H20) Ps=ABSOLUTE STACK PRESSURE

(IN. Hg) Pm=METER ABSOLUTE

PRESSURE

(IN. Hg) Pbar + (avg dH/13.6) TOTALS

98.9

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 21 of 30Run #1 BEGINNING ENDINGNET MOISTURE

DATA DIFF Baghouse

Outlet (Kiln #6) 7/20/2007 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 0..1NH2SO 0.1N H2SO, 0.1NNaOH

300 g SiO2 100 100

200

300.0 116 120

207

312.0 16 20

7 12.0 TOTALS

55.0

Run #2 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. o.1NH2SO 0.1NH2SO

0.1NNaOH

300 g SiO2 TOTALS BEGINNING 100

100

200

300.0 ENDING 124

111

203

314.6 NET 24

11

3 14.6

52.6

Run #3 1st Imp. 2nd Imp. 3rd/4th Imp 5th Imp. 0.1NH2SO 0.1NH2SO

0.1NNaOH

300 g SiO2 TOTALS BEGINNING 100

100

200

300.0 ENDING 124

129

217

311.5 NET 24

29

17

11.5

81,5 ISOKINETIC SAMPLING

RATE CALCULATION dH KdP K (846.72*Dn^4*dH@*Cp^2*(1-Bw)^2*Md*Tm*Ps)/(Ms*Ts*Pm)
Run #1 Run #2 Run #3 Module ID

Apex 2 Apex 2 Apex 2 Dn 0.257

0.257

0.257 dH@ 1.898

1.898

1.898 Y, gamma factor

0.999

0.999

0.999 Cp 0.84

0.84

0.84 Bw(FRA CTION, NOT%)

0.050

0.05

0.05 Md 29.00

29.00

29.00 Pbar 29.250

29.25

29.25 PS (GAUGE)

-0.42

-0.42

-0.42 Ps 29.22

29.22

29.22 Tm, F

80

93

90 Tm, R

539.69

552.69

549.69 Ms 28.45

28.45

28.45 Ts, F

440

455

455 Ts, R

899.69

914.69

914.69 Pm 29.36

29.38

29.38 K 2.7168

2.7351

2.7195 Terminology Ms=APPARENT STACK GAS MOLECULAR

WEIGHT =Md(1-Bw)+18Bw Md=DRY GAS MOLECULAR

WEIGHT (29) OR =(0.44*%CO2)+(0.32*%O2)+(0.28*(%N2+%CO)) Ps GAUGE=STACK

STATIC PRESSURE

(IN. H20) Ps=ABSOLUTE STACK PRESSURE

(IN. Hg) Pm=METER ABSOLUTE

PRESSURE

(IN. Hg) Pbar + (avg dH/13.6)
Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 22 of 30SAMPLE CALCULATIONS Boral Bricks E. Spencer,

NC Run #1 1) ABSOLUTE

PRESSURE

IN DRY GAS METER Pm P ATM + AVG DH/13.6 T ST[3P STD P ATM

Avg. DH

Pm
29.25 1.71

29,38 2) ABSOLUTE

STACK PRESSURE Ps P ATM + Ps(GAUGE)I13.6
P ATM Ps(GAUGE)

Ps
29.25 -0.42

29.22 3) SAMPLE VOLUME AT STANDARD

CONDITIONS VM STD (VM)*(Y)*(T

STD/TM)*(PM/P

STD)
Vm Tm

Y

Vm STD
42.30 544.02

0.999

40.27 ft3 4) VOLUME OF WATER COLLECTED,

CORRECTED

TO STANDARD

CONDITIONS W STD W STDw + WSTDsg
W STDw (.002673)*(VLQw)*(T

STD/P STD) W STDsg (.002668)*VLQsg)*(T

STD/P STD)
WHERE 0.002673

0.04707 FT3/ML*IN.

HG/17.64 DEC. R. WHERE 0.002668

0.04715 FT3/G*IN,HG/17.64

DEC. R. VLQ (w) VLQ (sg) W STD 43.00 12.00

2.59 ft3 5) TOTAL SAMPLE VOLUME AT STANDARD

CONDITIONS
V STD Vm STD + W STD 42.86 if3 6) PERCENT MOISTURE

IN STACK GAS %M (100)*(W STD)N STD 6,05% 7) MOLE FRACTION

OF DRY GAS
MD (100-%M)/100 0,939 528 DEC R. 29.92 IN. HG

Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 23 of 30SAMPLE CALCULATIONS Run #1 8) MOLECULAR

WEIGHT OF THE DRY GAS

MWD (%CO2*0.44)+(O2*0.32)+((%CO+%N2)*0.28)
%CO2 %02

%CO

%N2

MWD
3.0 16.4

0.0

80.6

29.13 9) MOLECULAR

WEIGHT OF THE WET GAS M (MWD)*(MD)

+ 18(1-MD) 28.46
WHERE 18 MOLECULAR

WEIGHT OF WATER, G/G-MOLE 10) STACK VELOCITY VS (85.49)*(CP)*(•SI(PS)(M))^112*((SUM SQRT DP)/N DP))
where 85.49 ft/sec* [Ibllb-mole*in.Hg)l(deg.

R'in H20)]^0.5
CP Ts (R) SUM SQRT

N DP VS 0.84 905.48

18.96

24

69.18 11) STACK VOLUMETRIC

FLOW RATE QS (60)*(VS)*(AS)
AS (inlet) QS 30.68 108,943 12) STACK VOLUMETRIC

FLOW RATE, STANDARD

CONDITIONS

INCLUDING

MOISTURE Q STD Q STD DRY/MD 62,038 13) STACK VOLUME FLOW RATE STANDARD

CONDITIONS

DRY Q STD DRY= 17.647*60*Md*Vs*A*(Ps/Ts(R)) 58,285 14) POLLUTANT

MASS RATE, CONCENTRATION

BASIS PMRC (. 1323)*(WT)*(Q

STD)N STD WHERE 0.1323 COMBINED

CONVERSION

FACTOR (60 MIN/HR*0.00220

LBS/GRAM) WT(GRAMS) PMRC 0.0008 0.153 15) PERCENT ISOKINETIC %1 (0.09460*Ts*Vm

std)/(Ps*Vs*An*Time*Md) Run Time Area of Nozzle 60 3.60E-04 %1 98.t2 16) CONCENTRATION,

GR/SCFD Cs= 15.43 gr/gm WTNm STD Cs 0.0003
Boral Bricks East Spencer,

NC (Kiln #6 DIFF BGHS Test) P-7099 Page 24 of 30